Company General Presentation Aquatech India Tomas Dornik, MEGA a.s., Czech Republic RALEX® - WATER TREATMENT To be preferred supplier of electro-chemical membrane processes providing superior solutions and services with maximum respect to the environment. RALEX® - WATER TREATMENT Our mission We are innovative and constantly growing private company with more than 25 years of experience in the production of ion-exchange membrane and supply of membrane technologies Family owned company (Mr. Lubos Novak, Ph.D.) author or co-author of patents (>20), research reports (>100) especially in the field of membrane processes, president of Czech Membrane Platform, founder of electro-membrane processes in CR Core business is production of ion-exchange membranes, spacers, membrane stacks and supply of complex electromembrane technologies on the basis of own know-how Processes and products are certificated by ISO (EU standards) and GOST-R (Russian Standards) RALEX® - WATER TREATMENT Company profile 1975 – 1981: Central laboratories of uranium industry (CSUP) • since April 1992: MEGA a.s. • 2000: MEGA-TEC s.r.o. 1981 – 1990: Research and Development Institute of CSUP • 2007: MEGA ProfiLine since 1985: Industrial production of membranes RALEX® • 2008: MemBrain 1991 – 1992: MEGA - VVÚ s.p. – state company • 2012: MEGA Ukraine 1995 2012 RALEX® - WATER TREATMENT History RALEX® - WATER TREATMENT Production Plant in Straz pod Ralskem RALEX® - WATER TREATMENT MEGA Group Subsidiary of MEGA a.s., Quick transfer of results of research works to industrial applications Headquarters: Stráž pod Ralskem, Czech Republic Founded: 2008 Employees: 56 Activities are mainly focusing into: - the latest processing trends in the field of membrane processes - electro-membrane processes - hybrid membrane processes - bipolar membranes - gas separation RALEX® - WATER TREATMENT MemBrain s.r.o. R&D (research and development) Membrane Innovation Center (MIC) is a unique Center focusing on research and innovation in membrane processes, which provides: new infrastructure for research and innovation activities modern equipment of analytical, technological and mobile laboratory net of industrial and academic organizations more than ten years experience in R&D support for education and popularization of the field RALEX® - WATER TREATMENT MemBrain s.r.o. Membrane Innovation Center (MIC) Our Offer in Membrane Processes Products Heterogenous ion-exchange RALEX membranes® (www.ralex.eu) Electrodialysis equipment (laboratory, pilot, industrial) Electrodeionization equipment Electrophoretic cells (flat, tubular) Membrane technologies (turn-key delivery) Electrochemical (ED(R), EDI) Complex process lines (integrated membrane processes) R&D and other services Consultancy, expertise, designing Laboratory and pilot scale trials Guarantee and post-guarantee service Staff training RALEX® - WATER TREATMENT Main Products & Applications ED, EDR, EDI, (RO) Water Food Special Apps Replacement E-coat Product EWTU, HPWU, (RWTU) EWDU ELPU RALEXEL, RALEX EFC Sludge lake water treatment Whey demineralization L-carnitine Desalination Membranes (GE-Ionics, Schekino) Anode cell tubular Ammonium nitrate condensate Mother liquor demineralization Gama–butyrobetain desalination Spacers (GE-Ionics) Anode cell flat Tertiary Treatment UF permeate demineralization Purification of organic solution Electrodes (GE-Ionics) Membrane tube Brackish water desalination Lactulose syrup demineralization Glycol purification ED Stacks (Eurodia) Membrane roll Waste water Re-use Skim-milk de-ashing Xylose Desalination Application Segment Ultra-pure water production Re-use of rinse water from galvanizing plant RALEX® - WATER TREATMENT Processes RALEX® - WATER TREATMENT Strategic partners: Definition of Electrodialysis Electrodialysis (ED) is an electrically-driven method of removing dissolved ionic compounds - Dissolved solids may exist in a form of ions that are either positively or negatively charged (cations or anions) - When an electrical potential is applied across the ion-selective membrane, cations migrate towards the negative electrode (cathode) and anions migrate towards positive electrode (anode) - The driving force is DC electric field RALEX® - WATER TREATMENT Definition and Characteristics of Ions Ions are nothing more than atoms or molecules that have gained or lost an electron(s). - Generated by salts, acids or alkalies dissociation in water - Both types – organic and inorganic - Independent movement in solution Cation is a positively charged (loosing of electron) ion - Cations migrate to the cathode Anion is a negatively charged (gaining of electron) ion - Anions migrate to the anode RALEX® - WATER TREATMENT Ion-exchange membranes present ion-selective barries Cation-exchange membranes (CM) - Selective transport of cations - Anionic transport blocked - Permselectivity about 96 % Anion-exchange membranes (AM) - Selective transport of anions - Cationic transport blocked - Permselectivity about 96 % RALEX® - WATER TREATMENT Ion-exchange Membranes Electrodialyzer – Heart of the ED Process Basic characteristics - Series of alternating ion-exchange membranes separated by spacers - One cation and one anion exchange membrane plus two spacers = cell pair - Spacers are alternately connected to internal manifolds for proper liquids distribution - Platinum-coated titanium electrodes RALEX® - WATER TREATMENT Electrodialyzer – Heart of the ED Process 1- Manifolds with built-in collectors 2 - Electrodes 4 - Spacers 5 - Tie-rods, washers and nuts 6 - Assembly pins RALEX® - WATER TREATMENT 3 - Ion exchange membranes RALEX EDR stacks for industrial applications Membrane stack EDR-III RALEX® - WATER TREATMENT Membrane Stack ED/EDR-II Small capacity EWT technology units P-series - EWTU P10 and EWTU P20 are compact, fully autonomous processing units for small size projects till 15 m3/hour (EWTU P10) and 20 m3/hour (EWTU P20); also suitable for piloting and/or testing - Both single pass and batch process applicable - Up to three stacks in series (for single pass mode) RALEX® - WATER TREATMENT Medium-capacity EWT technology units M-series - M45 and M90 are compact, fully autonomous processing units for mediumcapacity size projects till 45 m3/hour (EWTU M45) and till 90 m3/hour (EWTU M90); - Operating in single-pass through mode - M45 - arrangement in one line ; up to three stacks in series - M90 - arrangement in two lines; up to three stacks in series a s standard, can be designed with 2 concentration loops as four stages technology RALEX® EWTU M45 RALEX® EWTU M90 RALEX® - WATER TREATMENT Large scale EWT technology units TwinLine90 - Inlet hydraulic skid with reversal valves, pneumatic actuated - Two EDR lines, 2, 3 or 4 stages - Outlet hydraulic skid - Pipe collectors TwinLine90 12L/3S (approx. 500 m3/hour of product) One TwinLine90 RALEX® - WATER TREATMENT MEGA industrial applications of ED/EDR in Water Reuse and Desalination Water Reuse - of biologically pretreated waste waters to produce water for agricultural or landscape irrigation - of discharged water from industry to reuse it back to a process (as process water, make up water for cooling towers, RO brine recovery) - treatment of waste condensates from fertilizer industry to reuse ED concentrate back in the production process and diluate in water management of the company - … Desalination - of tailing ponds (mining industry) - of gas well waters - of brackish waters to produce drinking water - … RALEX® - WATER TREATMENT MEGA industrial applications of ED/EDR in Water Reuse and Desalination Desalination cost of various technologies E-Separation 10 $/m3 Cost Ion Exchange 1 $/m3 Reverse Osmosis 0,1 $/m3 IX EDR RO EDR 1 g/L 10 g/L 100 g/L TDS Evap RALEX® - WATER TREATMENT Evaporation MEGA projects in Water Reuse: Project “Depurbaix” Client: BEFESA/ACSA Project: Municipal waste water (tertiary) treatment to produce irrigation water Locality: Barcelona, Spain Commissioning: 2010 Feed specification: Municipal wastewater after biological and mechanical pre-treatment; 3200 microS/cm Quality of Product: < 750 microS/cm Capacity of product: 4x 12.000 m3/day (4x 500 m3/hour) MEGA technology: RALEX EWTU TwinLine90 48L/2S (EDR-III/600) Mode: Single pass, water recovery 86% RALEX® - WATER TREATMENT Desalination of biologically pretreated municipal waste water to produce water for agricultural irrigation MEGA projects in Water Reuse: Project “Depurbaix” RALEX® - WATER TREATMENT Desalination of biologically pretreated municipal waste water to produce water for agricultural irrigation MEGA projects in Water Reuse: Project “Depurbaix” Desalination of biologically pretreated municipal waste water to produce water for agricultural irrigation Process block scheme hypochlorite WWTP Actiflo® Secondary Coagulation, settler Injection, Maturation, Lamella Clarifier Discfilter Filtration Cartridge filtration Tailing pond K II Injection into aquifer to prevent saline intrusion Agricultural Irrigation ED UV Disinfection Sand filtration Feed into wetland areas Feed into river Llobregat RALEX® - WATER TREATMENT UF, RO, Ultraviolet MEGA projects in Water Reuse: Project „A.R.P.C.“ Client: GEMWATER/ ARAK PETROCHEMICAL CORPORATION Project: Desalination of biologically pretreated waste water from petrochemical plant to produce make up water for cooling towers Locality: Arak, Iran Commissioning: 2010 Feed specification: Wastewater after biological and mechanical pre-treatment, 1800 microS/cm Quality of Product: 85% of desalination degree (approx. 200-250 microS/cm) Capacity of product: 210 m3/hour MEGA technology: RALEX EWTU 6L/3S (EDR-III/500) Mode: Single pass, water recovery 85% RALEX® - WATER TREATMENT Desalination of biologically pretreated waste water to produce make up water for cooling towers MEGA projects in Water Reuse: Project „A.R.P.C.“ Tailing pond KI RALEX® - WATER TREATMENT Desalination of biologically pretreated municipal waste water to produce make up water for cooling towers MEGA projects in Water Reuse: Project „A.R.P.C.“ Desalination of biologically pretreated municipal waste water to produce make up water for cooling towers Clarifier Waste water from Complex Cooling tower make up Cartridge filters EDR DAF Activated sludge Sand filters + Carbon filters Evaporation pond RALEX® - WATER TREATMENT Process block scheme MEGA projects in Desalination: Project „GEAM“ Client: DIAMO s.p., zavod GEAM Project: Desalination of tailing ponds created by uranium mining Locality: Dolni Rozinka, Czech Republic Commissioning: 1986, extension 1995, extension 2007 Feed specification: Alkaline tailing pond waters from uranium mining with approx. 35 g/l TDS, containing, especially anions SO42- (20 g/l), NO3-, NO2-, cations NH4 , Na+, Ca2+, Mg 2+, other metals as Mo, organic matters, uranium U Pretreatment: Addition of lime and soda ash to precipitation Ca2+ and Mg2+ , sand filtration sorption of heavy metals and uranium on ionexchange colon filled by LEWATIT, sorption of organic solids on acivated carbon Capacity, composition: ED (membrane stacks ED-II) in Feed&Bleed mode - Feed: 65 m3/h, TDS approx. 35 g/l - Diluate: 50 m3/h, TDS 12-15 g/l; Concentrate: 15 m3/h, TDS min. 100g/l RO - Feed: 50 m3/h, TDS 12 g/l - Permeate: 35 m3/h, TDS less than 0,5 g/l; Retentate: 15 m3/h, TDS cca 40 g/l Quality of Product: Desalinated stream is discharged after pH controlle to a river, concentrate is evaporated to the final commercial product of pure Na2SO4 MEGA technology: Combination of ED and RO; ED: RALEX EWTU 30xED-II/200 ED Mode: Feed&Bleed RALEX® - WATER TREATMENT Desalination of tailing ponds (mining industry) MEGA projects in Desalination: Project „GEAM“ Tailing pond K I Tailing pond K II RALEX® - WATER TREATMENT Desalination of tailing ponds (mining industry) MEGA projects in Desalination: Project „GEAM“ Desalination of tailing ponds (mining industry) Evaporation, Na2SO4 crystalization Tailing pond water Lime,Na2CO3 Sorption of heavy metals and U (on ion exchange columns) Tailing pond RO K II ED Drainage water Ca and Mg Sand precipitation filtration GAC Filtration (sorption of organic solids) River RALEX® - WATER TREATMENT Process block scheme MEGA projects in Desalination: Project „ZSNP“ Client: ZSNP a.s. Project: Desalination of tailing ponds created after production of aluminium oxide Locality: Ziar nad Hronom, Slovakia Commissioning: 2003 Feed specification: Very high alkalinity waters (pH 13-14) from red mud tailing pond (nearly 10g/l of free NaOH, containing anions OH-, CO32-, cations Na+, K+, metals as Al (1g/l), heavy metals Cr, As, Mo, V and some organic matters) Pretreatment: Neutralisation with H2SO4 and precipitation using FeSO4 plus floccculant, sedimentation and filtration, additional acidification and double filtration before electrodialysis itself Capacity, composition: Feed: 14,4 m3/hr at 37 g/l TDS ; Diluate: 11,8 m3/hr at 6 g/l TDS; Concentrate: 2,6 m3/hr at 180 g/l TDS Quality of Product: Desalinated stream is discharged after pH controlle to a river, concentrate is evaporated to the final commercial product of pure Na2SO4 MEGA technology: ED: RALEX EWTU 12xED-II/200 Mode: Feed&Bleed RALEX® - WATER TREATMENT Desalination of tailing ponds (mining industry) MEGA projects in Desalination: Project „ZSNP“ DIVISON OF MEMBRANE PROCESSES Desalination of tailing ponds (mining industry) MEGA projects in Desalination: Project „ZSNP“ Desalination of tailing ponds (mining industry) Process block scheme NaClO2 (disinfection) H2SO4, FeSO4 Floculant H2SO4, NaClO2 (disinfection) Sand and anthracite filtration II Tailing pond water Neutralization, Sedimentation As and Cr precipitation ED Sand and Decarbonation anthracite (by air) filtration I Bag and Cartridge filtration River RALEX® - WATER TREATMENT Evaporation, Na2SO4 crystalization MEGA projects in Desalination: Project „GRP“ Client: GP RESOURCES Project: Small capacity unit - treatment of gas well waters Locality: Alberta-Calgary, Canada Commissioning: 2008 Feed specification: Gas well water, TDS in range 10 000 – 18 000 mg/l Quality of Product: Drinking water for hog barns, TDS under 500 mg/l Capacity of product: approx. 40 m3/day MEGA technology: RALEX EWTU P10 1xEDR-II/200-0.8; Mode: Batch RALEX® - WATER TREATMENT Desalination of gas well waters MEGA projects in Desalination: Project „GRP“ RALEX® - WATER TREATMENT Desalination of gas well waters MEGA projects in Desalination: Project „GRP“ Desalination of gas well waters Process block scheme Drinking water Gas well water filtration 1 µm Feed tank 1 EDR EDR GAC Filtration (sorption of hydrogencarbons) Feed tank 2 Brine tank RALEX® - WATER TREATMENT Bag MEGA projects in Desalination: Project „Llobregat-Abrera “ Client: Aigües del Ter-Llobregat (ATLL) Project: Pilot unit - treatment of river water to produce drinking water Locality: Abrera, Barcelona, Spain Commissioning: 2008 Feed specification: Trihalomethanes River water, < 2 000 microS/cm, problem s with high level of Quality of product: Potable water, 400-500 microS/cm Capacity of product: 10-12 m3/hour MEGA technology: RALEX EWTU P10 2xEDR-III/150-0.8 Mode: Single pass RALEX® - WATER TREATMENT Desalination of brackish waters to produce drinking water MEGA projects in Desalination: Project „Llobregat-Abrera “ RALEX® - WATER TREATMENT Desalination of brackish waters to produce drinking water MEGA projects in Desalination: Project „Llobregat-Abrera “ Desalination of brackish waters to produce drinking water KMnO4 Coagulant Floculant ClO2 GAC Filtration (dechlorination) Cl2 Cl2 Drinking water Llobregat River EDR CO2 Sedimentation Sand filtration CO2 Remineralization RALEX® - WATER TREATMENT Process block scheme MEGA projects in Chemical Industry: Project „JSC Minudobreniya “ Client: JSC MINUDOBRENIYA – Rossosh, Project: Treatment of waste waters from production of NPK in order to reuse ED concentrate back in the production process. Diluate stream is used in water management of the company. Locality: Rossosh, Russia Commissioning: 2012 Feed specification: 60 m3/hour of wastewater from ammonia nitrate production, 1,7 g/l (mainly NO3, NH4+) Requirement for product: ED concentrate approx.100 g/l (1 m3/h), diluate approx. 0,05 g/l (59 m3/h) MEGA technology: Pretreatment - Sand filtration plus microfiltration RALEX® EWTU М90 2L/4S EDR-III/600; RALEX® EWTU P15 2xEDII/250; Mode: 1. part: Basic demineralization on RALEX® EWTU M90 2L/4S EDR-III/600 operating in one-pass mode 2. part: The concentration on the two units RALEX® EWTU P15 2xEDII/250 operating in batch mode RALEX® - WATER TREATMENT Treatment of waste waters from fertilizer industry MEGA projects in Chemical Industry: Project „JSC Minudobreniya “ RALEX® - WATER TREATMENT Treatment of waste waters from fertilizer industry MEGA projects in Water Reuse: Project „JSC Minudobreniya - Rossosh“ Treatment of waste waters from fertilizer industry Pretreatment Electromembrane processes Product 1: Diluate Feed water TDS = 1,7 g/l EWTU M90 2L/4S Buffer tank TDS = 0,05 g/l EDRIII/600 Sand MF filtration 2 x EWTU P15 ED-II/250 Product 2: Concentrate (NH4NO3) TDS above 100 g/l RALEX® - WATER TREATMENT Process block scheme Unit A25 feed 25 m3.h-1, TDS 3.0 g.l-1 (as NH4NO3), temp. 20 – 40°C diluate TDS 0.10 – 0.25 g.l-1 concentrate TDS 100 – 200 g.l-1 energy consumption 3.5 kWh.m-3 (of upper defined feed) RALEX® - WATER TREATMENT Nominal Parameters RALEX® - WATER TREATMENT Unit A25 Unit A25 without intermediate tanks, pumps and instrumentation compact footprint optimized membrane area the same spare parts for both types of membrane stacks all main components doubled possibility to have 1 line in operation and 1 line in repair or CIP fast start to full production with constant products quality no waste production even during CIP (reprocessing by A25) RALEX® - WATER TREATMENT Advantages in Comparison to the Conventional ED Concept MEGA projects in Chemical Industry: Project „Kuybyshev AZOT“ Client: AO KUYBYSHEV AZOT Project: Treatment of waste waters from production of NPK in order to reuse ED concentrate back in the production process. Diluate stream is used in water management of the company. Locality: Togliatti, Russia Commissioning: 2013 Feed specification: 60 m3/hour of wastewater from ammonia nitrate production, 2,9g/l Requirement for product: ED concentrate approx.120 g/l, diluate approx. 0,04 g/l; MEGA technology: 2xRALEX® RALEX® EWTU М90 2L/4S EDR-III/600; RALEX® EWTU 4xED-II/250; EWTU HPW P32 8xEDI-X Mode: 1. part: Basic demineralization on RALEX® EWTU M90 2L/4S EDR-III/600 operating in one-pass mode 2. part: The concentration on the two units RALEX® EWTU 4xED-II/250 operating in batch mode RALEX® - WATER TREATMENT Treatment of waste waters from fertilizer industry MEGA projects in Chemical Industry: Project „Kuybyshev AZOT“ RALEX® - WATER TREATMENT Treatment of waste waters from fertilizer industry MEGA projects in Chemical Industry: Project „Kuybyshev AZOT“ Treatment of waste waters from fertilizer industry Pretreatment Feed water TDS = 2,9 g/l Electromembrane processes Product 1: Diluate TDS = 0,04 g/l EWTU M90 2L/4S Buffer tank EWTU HPW P32 8xEDI-X EDRIII/600 MF EWTU 4xEDII/250 Product 2: Concentrate (NH4NO3) TDS above 120 g/l RALEX® - WATER TREATMENT Process block scheme MEGA projects in Water Reuse: Project „Petrochemical Complex Comperj “ Client: VWS Brasil Ltda Project: for Desalination pretreated industrial waste water after MBR to prepare water further industrial usage in a petrochemical complex Locality: Itaboraí – Rio de Janeiro, Brasil Commissioning: supposed 2014 Feed specification: Industrial waste waters after MBR; TDS 1200mg/l Quality of Product: TDS 210 mg/l Capacity of product: 425 m3/hour MEGA technology: RALEX EWTU TwinLine90 12L/3S (EDR-III/550) Mode: Single pass, water recovery 85% RALEX® - WATER TREATMENT Desalination of mechanically and biologically pretreated industrial waste water for further industrial usage MEGA projects in Water Reuse: Project „Petrochemical Complex Comperj “ RALEX® - WATER TREATMENT Desalination of mechanically and biologically pretreated industrial waste water for further industrial usage MEGA projects in Water Reuse: Project „Petrochemical Complex Comperj “ Desalination of mechanically and biologically pretreated industrial waste water for further industrial usage Process block scheme Boiler feed Oil separator EDR MBR DAF Nut schell filter Carbon filters RO RALEX® - WATER TREATMENT Mix Bed Waste water from Complex MEGA projects in Water Reuse: Project „Achinsk“ Client: BIOTECHPROGRESS Project: water Desalination of mechanicaly and biologically pretreated industrial waste to achieve the ecological limits for discharge to watercourse Locality: Krasnoyarsk, Russia Commissioning: supposed 2014-2015 Feed specification: Industrial waste waters after biological and mechanical pretreatment; TDS 1300mg/l Quality of Product: TDS 500 mg/l Capacity of product: 500 m3/hour MEGA technology: RALEX EWTU TwinLine90 12L/2S (EDR-III/550) + 6L/2S Mode: Single pass, water recovery 85% RALEX® - WATER TREATMENT Desalination of mechanically and biologically pretreated industrial waste water to achieve the limits for discharge MEGA projects in Water Reuse: Project „Achinsk“ Desalination of mechanically and biologically pretreated industrial waste water to achieve the limits for discharge Bag filtration (TSS removal) Tailing pond Diluate TDS = 0,37 g/l K II Feed water TDS = 1,3 g/l MBR EDR RO Organic removal Crystalization Concentrate TDS = 7 g/l RALEX® - WATER TREATMENT Process block scheme MEGA projects in Desalination: „Project Belkhir“ Client: METITO Project: Drinking water supply Locality: Belkhir, Tunisia Commissioning: supposed 2014 Feed specification: Well water, TDS 2500 mg/l Quality of Product: Drinking water, TDS under 1000 mg/l Capacity of product: approx. 2x 800 m3/day MEGA technology: 2x RALEX EWTU M45 2xEDR-III/500-0.8; Mode: Single pass, water recovery 85% RALEX® - WATER TREATMENT Desalination of well waters to produce drinking water MEGA projects in Desalination: „Project Belkhir“ Desalination of well waters to produce drinking water Drinking water supply < 1 g/l Cartridge filters Well water 2,5 g/l EDR Sand filters Evaporation pond 12,2 g/l RALEX® - WATER TREATMENT Process block scheme EDI Process – How does it work RALEX® - WATER TREATMENT The EDI process uses ionexchange membranes in combination with ion-exchange resin to provide a high purity water. MEGA Pure means MPure Application: industrial high purity water Reduce system complexity and cost Equal or better DI & Silica performance vs. state-of-the-art EDI Improved mechanical construction Improve stack robustness Cost competitive also for large flow rates RALEX® - WATER TREATMENT M36 Product Requirements Flow rate 10-15 m3/h per stack Low system cost Interconnection up to 3 stacks Competitive with MB High Recovery Hardness Tolerance RALEX® - WATER TREATMENT M36 Product Requirements RALEX® - WATER TREATMENT GEAM Demonstration Unit RALEX® - WATER TREATMENT Mpure Three Stack System RALEX® - WATER TREATMENT Mpure Three Stack System EXPERIENCE: MEGA has long-term experience in developing, designing, manufacturing and supplying of electrodialysis (since 1985). PROVEN AND REASONABLE: MEGA has a significant market position in electrodialysis supply for different applications and industries (reference list upon request) KNOWLEDGE: MEGA has long-term R&D co-operation with reputable institutions concerning whey treatment and MEGA ProfiLine develops new dairy products based on demineralized whey. R&D subsidiary MemBrain Ltd. received budget approval for building and operation of Membrane Innovative Centre in the Czech Republic. EU ORIGIN, SHORT DELIVERY TIME (for European & CIS customers): MEGA manufactures all key components for ED (membranes, spacers, stacks, equipment) based on own know-how in plant located in Central Europe. MEGA ProfiLine keeps main spare parts and consumables in local warehouse in Russia. RALEX® - WATER TREATMENT Why consider MEGA as supplier? G11 Thank you for your attention. RALEX® - WATER TREATMENT